Reinforced container

• US 5,850,965 A
• Filed: 06/17/1997
• Issued: 12/22/1998
• Est. Priority Date: 06/17/1997
• Status: Expired due to Term

• Current Assignee: Dell USA LP (Dell Technologies Inc.)
• Original Assignee: Dell USA LP (Dell Technologies Inc.)
• Inventors: Boyls, Derek W., Bridges, John W.
• Primary Examiner(s): Shoap, Allan N.
• Assistant Examiner(s): Mai, Tri M.
• Application Number:
  US08/877,693
• Time in Patent Office: 553 Days
• Field of Search: 229/191, 229/184, 229/183, 229/192, 229/193, 229/198.2, 229/132, 229/918, 229/199, 206/503
• US Class Current: 229/191
• CPC Class Codes: B65D 5/0227 with end closures formed by inward folding of flaps and securing them by heat-sealing, by applying adhesive to the flaps or by staples
• CPC Class Codes: B65D 5/443 Integral reinforcements, e.g. folds, flaps double walls B65D5/02

Abstract

A reinforced container includes four exterior panels and four supports. Three of the supports are integrally connected to two exterior panels that are positioned to form an edge of the container. The supports can be secured to the interior sides of the exterior panels. The reinforced container can be made from folding a single sheet of corrugated fiberboard.

Claims

1. A container comprising:

a first side panel having an interior side;

a second side panel;

a first support integrally connected to a first edge of the first side panel, the first support integrally connected to a first edge of the second side panel, the first edge of the first side panel and the first edge of the second side panel positioned to form a first edge of the container;

a first flap;

a second support integrally connected to a second edge of the first side panel, the first support integrally connected to a first edge of the first flap, the second edge of the first side panel and the first edge of the first flap positioned to form a second edge of the container;

wherein the first edge of the first side panel and the second edge of the first side panel are adjacent edges;

wherein an end of at least a portion of the first support is mitered and an end of at least a portion of the second support is mitered such that the at least the portions of the first and second supports fit against the interior side of the first side panel and the mitered end of the at least the portion of the first support is adjacent to the mitered end of the at least the portion of the second support.

2. The container of claim 1 wherein:

the first support is integrally connected to at least a majority of the first edge of the first side panel; and

the first support is integrally connected to at least a majority of the first edge of the second side panel.

3. The container of claim 1 further comprising:

a third side panel;

a third support integrally connected to a third edge of the first side panel, the second support integrally connected to a first edge of the third side panel, the first side panel and the third side panel positioned to form a third edge of the container;

wherein an end of at least a portion of the third support is mitered and an second end of at least a portion of the second support is mitered such that the at least the portions of the first and third supports fit against the interior side of the first side panel.

4. The container of claim 1, wherein:

the at least a first potion of the first support includes a first support panel having a first edge integrally connected to the the first edge of the first side panel, wherein a second edge of the first support panel is mitered; and

.

5. The container of claim 4 wherein a first side of a first support panel is secured to the interior side of the first side panel.

6. The container of claim 4 wherein a first side of the first support panel is secured to an interior side of the first side panel with glue.

7. The container of claim 4, wherein:

the at least the portion of the first support further includes;

a first intermediate support panel having a first edge integrally connected to a third edge of the first support panel, the first intermediate support having a third edge being mitered;

the first support further includes a second portion, the second portion including;

a second support panel having a first edge integrally connected to the first edge of the second side panel, the second support panel having a third edge being mitered;

a second intermediate support panel having a first edge integrally connected to a second edge of the second support panel, the second intermediate support panel having a third edge being mitered;

wherein a second edge of the first intermediate support panel is integrally connected to a second edge of the second intermediate support panel.

8. The container of claim 7 wherein:

the integral connection of the first edge of the first intermediate support panel to the third edge of the first support panel is perforated; and

the integral connection of the first edge of the second intermediate support panel to the second edge of the second support panel is perforated.

9. The container of claim 7 wherein:

a first side of the first support panel is secured to an interior side of the first side panel;

a first side of the second support panel is secured to an interior side of the second side panel;

a second side of the first support panel is secured to a first side of the first intermediate support panel; and

a second side of the second support panel is secured to a first side of the second intermediate support panel.

10. The container of claim 1 wherein:

the edge of the container has an interior side, the first support is located on the interior side.

11. The container of claim 1 wherein the first side panel, the second side panel, the first flap, the first support, and the second support are made of corrugated fiberboard.

12. The container of claim 11 wherein:

the fiberboard has a corrugated direction;

the first side panel and the second side panel have vertical edges substantially parallel to the corrugated direction.

13. The container of claim 1 wherein the first side panel and the second side panel are vertical panels.

14. The container of claim 1 wherein the end of the at least a portion of the first support and the end of the at least a portion of the second support are mitered at an approximate 45 degree angles.

15. The container of claim 1 further comprising:

a second flap;

a third support integrally connected to a second edge of the second side panel, the first support integrally connected to a first edge of the second flap, the second edge of the second side panel and the first edge of the second flap positioned to form a third edge of the container;

wherein the first edge of the second side panel and the second edge of the second side panel are adjacent edges;

wherein the second side panel has an interior side;

wherein an end of a second portion of the first support is mitered and an end of at least a portion of the third support is mitered such that the second portion of the first support and the at least the portion of the third support fit against the interior side of the second side panel.

16. The container of claim 15 wherein:

the first flap and the second flap are positionable to form a container side;

an end of a second portion of the second support is mitered and an end of a second portion of the third support is mitered such that the second portion of the second support and the second portion of the third support fit against an interior side of the container.

17. The container of claim 1 wherein the end of at least a portion of the first support is mitered at an angle and the end of at least a portion of the second support is mitered at an angle such that the at least the portions of the first and second supports fit together against the interior side of the first side panel.

18. A sheet of material for making a container comprising:

a first side panel;

a second side panel;

a first flap;

a first intermediate portion integrally connected to the first side panel at a first joint, the first intermediate portion integrally connected to the second side panel at a second joint;

a second intermediate portion integrally connected to the first side panel at a third joint, the second intermediate portion integrally connected to the first flat at a fourth joint;

wherein the first intermediate portion is used to form a first support when the first side panel is positioned with the second side panel to form a first edge of the container;

wherein the second intermediate portion is used to form a second support when a container has been formed from the sheet of material;

wherein an end of the first intermediate portion has a form such that at least a portion of the first support is mitered and an end of the second intermediate portion has a form such that at least a portion of the second support is mitered such that the at least the portions of the first and second supports fit against the interior side of the first side panel with the mitered end of the at least a portion of the first support positioned adjacent to the mitered end of the at least a portion of the second support when a container has been formed from the sheet of material.

19. The sheet of claim 18 wherein the first intermediate portion includes:

a first support panel integrally connected to the first side panel at the first joint; and

a second support panel integrally connected to the second side panel at the second joint;

the first support panel and the second support panel are integrally coupled.

20. The sheet of claim 19 wherein the first intermediate portion further includes:

a first intermediate support panel integrally connected to the first support panel at a fifth joint;

a second intermediate support panel integrally connected to the second support panel at a sixth joint;

wherein the first intermediate support panel and the second intermediate support panel are integrally connected at a seventh joint; and

wherein the sheet of material is folded at the first joint, the second joint, the fifth joint, the sixth joint, and the seventh joint to form the first support when the sheet is formed into a container.

21. The sheet of claim 20 wherein

the first, fifth, and seventh joints are folded in a first direction when the first side panel is positioned with the second side panel to form the first edge of the container;

the second and sixth joints are folded in a second direction when the first side panel is positioned with the second side panel to form the first edge of the container; and

the first direction is in the opposite direction of the second direction.

22. The sheet of claim 20 wherein:

the first, fifth, and seventh joints are formed by scoring the sheet; and

the second and sixth joints are formed by perforating the sheet.

23. The sheet of claim 20 wherein the first, fifth, and seventh joints each extend out farther from the end of the first intermediate support than each of the second and fourth joints.

24. The sheet of claim 18 further comprising;

a third side panel;

a third intermediate portion integrally connected to the first side panel at a fifth joint, the third intermediate portion integrally connected to the third side panel at a sixth joint;

wherein the third intermediate portion is used to form a third support when the first side panel is positioned with the third side panel to form a second edge of the container;

wherein an end of the third intermediate portion has a form such that at least a portion of the third support is mitered and a second end of the second intermediate portion has a form such that a second end of the at least the portion of the second support is mitered such that the at least the portions of the third and second supports fit against the interior side of the first side panel.

25. The sheet of claims 24 wherein

the first and second joints are substantially parallel;

the third and fourth joints are substantially parallel; and

the first and third joints are substantially perpendicular.

26. The sheet of claim 18 further comprising:

a second flap;

a third intermediate portion integrally connected to the second side panel at a fifth joint, the third intermediate portion integrally connected to the second flap at a sixth joint;

wherein the third intermediate portion is used to form a third support when a container has been formed from the sheet of material;

wherein the end of the first intermediate portion has a form such that a second portion of the first support is mitered and an end of the third intermediate portion has a form such that at least a portion of the third support is mitered such that the second portion of the first support and the at least the portion of the third supports fit against the interior side of the second side panel.

27. The sheet of claim 26 wherein:

the first flap and the second flap are position to form a container side;

the end of the second intermediate portion and the end of the third intermediate portion have a form such that a second portion of the second support and a second portion of the third support have mitered ends such that the second portion of the second support and the second portion of the third support fit against the interior side of the container side.

28. The sheet of claim 26 wherein:

the form of the end of the first intermediate portion is generally a saw tooth form;

the form of the end of the second intermediate portion is generally a saw tooth form.

29. The sheet of claim 18 wherein the material is corrugated fiberboard.

30. The sheet of claim 29 wherein:

the corrugated fiberboard having a corrugated direction, the first and second joints are substantially parallel with the corrugated direction.

31. The container of claim 18 wherein the end of the at least a portion of the first support the end of the at least a portion of the second support are mitered at an approximate 45 degree angles.

32. A sheet of material for making a container comprising:

a first exterior panel;

a second exterior panel;

a third exterior panel;

a fourth exterior panel;

a first intermediate portion of a first type integrally connected to the first exterior panel and to the second exterior panel;

a second intermediate portion of the first type integrally connected to the second exterior panel and to the third exterior panel;

a third intermediate portion of the first type integrally connected to the third exterior panel and to the fourth exterior panel;

a first flap integrally coupled to the first exterior panel;

a second flap;

a third flap integrally coupled to the second exterior panel;

a fourth flap;

a fifth flap integrally coupled to the third exterior panel;

a sixth flap;

a seventh flap integrally coupled to the fourth exterior panel;

an eighth flap;

a first intermediate portion of a second type integrally connected to the first exterior panel and to the second flap;

a second intermediate portion of the second type integrally connected to the second exterior panel and to the fourth flap;

a third intermediate portion of the second type integrally connected to the third exterior panel and to the sixth flap;

a fourth intermediate portion of the second type integrally connected to the fourth exterior panel and to the eighth flap;

wherein each intermediate portion of the first type includes;

a first support panel integrally connected at a first joint to one of the exterior panels integrally connected to the intermediate portion, the first support panel having an end mitered at an angle;

a second support panel integrally connected at a second joint to the other of the exterior panels integrally connected to the intermediate portion, the second support panel having an end mitered at an angle;

a first intermediate support panel integrally connected to the first support panel at a third joint, the first intermediate support panel having an end mitered at an angle;

a second intermediate support panel integrally connected to the second support panel at a fourth joint, the second intermediate support panel having an end mitered at an angle;

wherein the first intermediate support panel and the second intermediate support panel are integrally connected at a fifth joint;

wherein the sheet of material is folded at the first joint, the second joint, the third joint, the fourth joint, and the fifth joint to form a support when the sheet is formed into a container;

wherein each intermediate portion of the second type includes;

a first support panel integrally connected at a first joint to an exterior panel integrally connected to the intermediate portion, the first support panel having a first end mitered at an angle and a second end mitered at an angle;

a second support panel integrally connected at a second joint to a flap integrally connected to the intermediate portion, the second support panel having a first end mitered at an angle and a second end mitered at an angle;

a first intermediate support panel integrally connected to the first support panel at a third joint, the first intermediate support panel having a first end mitered at an angle and a second end mitered at an angle;

a second intermediate support panel integrally connected to the second support panel at a fourth joint, the second intermediate support panel having a first end mitered at an angle and a second end mitered at an angle;

wherein the first intermediate support panel and the second intermediate support panel are integrally connected at a fifth joint;

wherein the sheet of material is folded at the first joint, the second joint, the third joint, the fourth joint, and the fifth joint to form a support when the sheet is formed into a container;

a portion integrally connected to the fourth exterior panel, the portion including;

a first support panel integrally connected at a first joint to the fourth exterior panel, the first support panel having an end mitered at an angle;

a second support panel, the second support panel having an end mitered at an angle;

a first intermediate support panel integrally connected to the first support panel at a second joint, the first intermediate support panel having an end mitered at an angle;

a second intermediate support panel integrally connected to the second support panel at a third joint, the second intermediate support panel having an end mitered at an angle;

wherein the first intermediate support panel and the second intermediate support panel are integrally connected at a fourth joint;

wherein the sheet of material is folded at the first joint, the second joint, the third joint, and the fourth joint to form a support when the sheet is formed into a container; and

wherein a first side of the second support panel of the portion is secured to an interior side of the first exterior panel when the sheet is formed into a container;

wherein the first, third, fifth, and seventh flaps are positioned to form a first container side when the sheet is formed into a container; and

wherein the second, fourth, sixth, and eighth flaps are positionable to form a second container side when the sheet is formed into a container;

wherein the first support panels of the intermediate portions of the first and second types having mitered ends enables each first support panel of the intermediate portions of the first type to be positioned adjacent to a first support panel of an intermediate portion of the second type against an interior side of an exterior panel when the sheet is formed into a container.

33. The sheet of material of claim 32 wherein:

each intermediate portion of the first type includes a portion edge, the portion edge including the edges that are mitered of the first support panel, the second support panel, the first intermediate support panel, and the second intermediate support panel of the intermediate portion of the first type, the portion edge of the intermediate portion of the first type having a generally saw-toothed form;

each intermediate portion of the second type includes a first portion edge, the first portion edge including the first edges that are mitered of the first support panel, the second support panel, the first intermediate support panel, and the second intermediate support panel of the intermediate portion of the second type, the first portion edge of the intermediate portion of the second type having a generally saw-toothed form; and

each intermediate portion of the second type includes a second portion edge, the second portion edge including the second edges that are mitered of the first support panel, the second support panel, the first intermediate support panel, and the second intermediate support panel of the intermediate portion of the second type, the second portion edge of the intermediate portion of the second type having a generally saw-toothed form.

34. A container comprising:

four side panels, each side panel having an interior side, the panels forming four container edges of a first type, each container edge of the first type having a generally parallel orientation with respect to the other container edges of the first type;

a plurality of flaps positionable to form a container side, the container side and the four side panels forming four container edges of a second type, each container edge of the second type having a generally perpendicular orientation with respect to each container edge of the first type;

four supports of a first type each located on an interior side of a container edge of the first type;

four supports of a second type each located on an interior side of a container edge of the second type;

wherein each of the four supports of the first type has a mitered end and each of the four supports of the second type has two mitered ends such that each support of the first type fits against the interior sides of the two side panels that form the container edge of the first type in which the support of the first type is located and each support of the second type fits against an interior side of the container side and the interior side of the side panel that form the container edge of the second type in which the support of the second type is located.

35. The container of claim 34 wherein the mitered ends of the four supports of the first type and of the four supports of the second type each having two portions mitered at an approximate 45 degree angles.